Tandem batch feed and tandem batch collection apparatus for continuous pyrolysis of rubber and/or other hydrocarbon-based material

Abstract

An apparatus for vacuum pyrolysis of rubber and/or other hydrocarbon material is provided. The apparatus includes tandem batch feed hoppers operated sequentially under vacuum to continuously feed the pyrolysis reactor, and tandem batch collection bins operated in sequence under vacuum to collect the reaction product from the reactor. A process for vacuum pyrolysis is also provided.

What is claimed is:  
     
         1 . A continuous feed/continuous collection apparatus for pyrolysis of rubber and/or hydrocarbon-based material, comprising: 
 a feed system for transferring rubber and/or hydrocarbon-based material cuttings to an inlet of a low temperature reactor chamber, wherein said feed system comprises a plurality of hoppers operated in sequence, each hopper having a vacuum-sealable slide valve adjacent a top and a bottom of the hopper.    
     
     
         2 . A continuous feed/continuous collection apparatus according to  claim 1 , further comprising a continuous transport system within the reactor chamber that moves a reaction product through spatially varying temperature zones.  
     
     
         3 . A continuous feed/continuous collection apparatus according to  claim 1 , further comprising a collection system for collecting a solid reaction product from a reactor chamber outlet.  
     
     
         4 . An apparatus for reclamation and recovery of constituents of discarded vehicle tires and other rubber-based materials including organic and inorganic materials for reuse or environmentally-safe disposal, comprising: 
 a feed system for transferring rubber-based material to an inlet of a low temperature reactor chamber, said low temperature reactor chamber having activation, decomposition, and completion zones and having a helicoid auger for transferring pieces of the rubber-based material from the reactor inlet and solid product from a reactor outlet;    inlet and outlet bins positioned at each end of the low temperature reactor chamber;    a solid material recovery system; and    a vapor recovery system for recovering vapor from the decomposition zone of said low temperature reactor chamber.    
     
     
         5 . An apparatus according to  claim 4 , wherein said vapor recovery system comprises: 
 a heat exchanger for condensing vapor from said low temperature reactor chamber;    a liquid/vapor separator for separating liquids condensed in said heat exchanger; and    a vacuum pump for removing vapor from the decomposition zone of said low temperature reactor chamber through said heat exchanger and said liquid/vapor separator and maintaining a vacuum in said low temperature reactor chamber.    
     
     
         6 . A continuous feed/continuous collection apparatus according to  claim 2 , wherein said continuous transport system comprises a helicoid auger.  
     
     
         7 . A process for treating rubber and/or hydrocarbon-based material by vacuum pyrolysis, comprising: 
 transferring rubber and/or hydrocarbon-based material to an inlet of a low-temperature reactor chamber by a plurality of hoppers operated sequentially in vacuum and at atmospheric pressure;    vacuum pyrolyzing the rubber and/or hydrocarbon-based material, thereby yielding a carbon black/carbonaceous solid residue, a liquid hydrocarbon product, wire, and a non-condensable combustible vapor.    
     
     
         8 . A process according to  claim 7 , further comprising fragmenting the rubber and/or hydrocarbon-based material to approximately 10×10 inch or smaller cuttings.  
     
     
         9 . A process according to  claim 7 , further comprising fragmenting the rubber and/or hydrocarbon-based material without previous separation of cords and steel threads.  
     
     
         10 . A process according to  claim 7 , further comprising heating the reactor to control a pyrolysis temperature.  
     
     
         11 . A process according to  claim 10 , further comprising maintaining the pyrolysis temperature through controlled spatially heating of the reactor to maintain a reaction temperature.  
     
     
         12 . A process according to  claim 7 , wherein the rubber or hydrocarbon-based material comprises discarded vehicle tires.